Metal Cutting

Material removal through cutting, turning, milling, drilling, grinding, tapping and more using machinery such as laser cutting systems, plasma cutting systems, oxyfuel cutting systems, milling machines, drill presses, lathes, horizontal machining centers, vertical machining centers, turning centers, multitasking machines, electrical discharge machines and other equipment assisted by Computer Aided Design (CAD), Computer Aided Manufacturing (CAM), Computer Numerical Control (CNC), automation and robotics.

What Lies Ahead in Real Time

The Holy Grail in manufacturing automation lies in machine tool monitoring and the growing impact of network communications on equipment effectiveness for manufacturers.
Experts
Automation/Robotics

Internet 4.0 Innovations for Machine Tools

Using an integrated Beckhoff control computer, the 701S micromachining center from Willemin-Macodel delivers path accuracy better than 0.2 μm, low sensitivity to temperature fluctuations and very high precision and repeatability at a maximum speed of 80,000 rpm – without tool holders, which increases static and dynamic rigidity and results in very high balancing quality and a low radial runout (less than 1 μm at the tool tip).
Take a look at how PC-based control technology is turning visionary Industry 4.0 concepts into profitable "smart factories" through the use of Google Glass in automation, all-in-one robot and machine tool control, and standard OPC UA connectivity.
CAD/CAM Software

Mission Accomplished

Robotic metal polishing; Mico Industries.
Thanks to SolidCAM iMachining, cycle times are down 50 percent, tool life is up 40 percent, and Mico Industries is creating dies, weld fixtures and check fixtures without compromise.
Drilling Machines

Making Natural Gas Clean with a “Hole” Lot of Pressure

A pressure vessel in the mid-fabrication stages. The pressure vessels Mueller Environmental manufacturers measure anywhere from 4 ft to 8 ft in diameter and are made from ½ in to 3 1/2 in thick 5617 rolled steel plate. The diameter and material thickness depends upon the pressure the vessel must withstand. Sometimes pressures can reach as high as 3,000 psi.
Using a modified HMD915 magnetic drill and Industrial Series of Rotabroach Cutters from Hougen enabled Mueller Environmental to cost-effectively develop a patented new system for cleaning natural gas.
Gear Cutting Machines

Gear Production: Higher Speed, Closer Precision

The accuracy of the Fast Gear Alignment function eliminates the need to acquire acoustic signatures during dressing or grinding. Aligning a grinding wheel with a 180 mm diameter gear with 71 helical teeth takes just 0.5 of a second – without any need to acquire acoustic signatures or make manual adjustments. 
Automated threaded wheel grinding on gear production machines has now been boosted by an order of magnitude with increased machining accuracy to DIN class 3.
Grinding Machines

Gear Hobbers and Control Migration

All seven axes on the 400H Series II gear hobber, including the 560 Nm work piece spindle motor, are controlled by NUMDrive C servo drives and a Flexium 68 CNC system. (first view)
This is the story of how Bourn & Koch upgraded its older gear hobbers to advanced CNC systems to machine large bull and cluster gears, worms, shafts, splines and pinions for the defense and aerospace, oil/gas drilling, mining, heavy equipment and power generation industries.
Honing Machines

A Chip Off the Old Block

Dart produces about 16,000 cylinder heads per year.
Dart masters the "peaks and valleys" of custom engine block production with an advanced American-made Sunnen SV-20 flexible honing system that uses programmable control to replicate “best” engine parameters and produce expert results with minimal operator expertise.
Horizontal Machining Centers

Horizontal Machining vs. Vertical Machining: Rethinking Your Operation

A horizontal machining center provides additional access to the part. Since multiple faces of a workpiece can be machined in a single setup, a part that takes six operations on a vertical machine can be completed in just two on a horizontal. This means better quality parts, reduced setups, handling and machining time – all of which are ideal for low-volume, repeat work.  
If the manufacturer is able to move past the sticker price and examine the dollars spent making the part, or the cost per part, a multitude of qualities can factor into the machine tool’s return on investment. Here are some reasons why a less expensive piece of equipment is not always the obvious choice.
Laser Cutting

Micromachining: No More Constraints

Prototyping time for new nozzle designs is reduced from weeks in the machine shop to 24 hours with the R-Drill, dramatically accelerating design optimization and time to market. The R-Drill reduces drilling time by approximately 30 percent while increasing yield to nearly 100 percent, with no need for expensive post-processing to correct HAZ damage.
The latest femtosecond laser technology from Raydiance can reduce cost per part by 20 percent to 50 percent and reduce product design, prototyping and development from months to as little as 24 hours.
Lathes

Hard Thread Turning Shortens The Process Chain

Figure 1. High rigidity allows higher process forces: Hembrug turning machines are especially suitable for high-precision hard turning.
High precision hard turning techniques are enjoying ever greater popularity in the metal processing industry. By shortening cycle times and increasing flexibility, high precision hard turning has advantages over grinding in particular when it comes to processing complicated parts such as spindle nuts or threaded spindles in the hard state.
Machine Controls

Guitar Hero

Right-angle head compensation is essential to the accurate milling of guitar neck components. The function requires the sophisticated Sinumerik 840D sl CNC and ShopMill software from Siemens. Guitar image courtesy of C.F. Martin & Company. (first view)
How CNC machining takes center stage in high-quality guitar craftsmanship.
Milling Machines

Boring Mill Fuels Energy Sector Expansion for Machine Shop

The dual-pallet, rotary table Giddings & Lewis MC 1600 horizontal boring mill (HBM) from Fives is designed for multi-axis contour milling, precision boring, drilling and tapping. It will produce a variety of large parts for Milwaukee Machine Works, including wind turbine gearbox housings and fluid end manifolds for the oil/gas industry.
Milwaukee Machine Works expands its energy sector business into wind turbine gearbox housings, fluid end manifolds for the oil/gas industry, and other oversized components up to 10 ft long and weighing up to 7,000 lb with a new large capacity dual-pallet Giddings & Lewis MC 1600 from Fives.
Multitasking Machines

Shoot from the Hip

Custom shoulder implant parts on the NTX 2000 turn-mill center, which has opened up new possibilities for parts that previously required at least two operations. Rasp handles that were previously contracted outside will become some of the first components loaded on the new machine.
This orthopedics manufacturer achieves one hit machining in an automated lights-out environment using advanced turn-mill machines that take their custom implants for coated hip replacement to a whole new efficiency.
Ram EDM Machines

A Hole New Game: Precision EDM Holemaking Goes Smaller, Deeper and Faster

Technically advanced EDM drill systems merge hole popper technology with die-sinker digital generator technology for more precise spark control that essentially puts the holemaking accuracy in the technological hands of the machine tool.
While hole-popper systems are quite capable of generating very small accurate holes with good surface quality, advanced EDM drilling systems dramatically increase a shop’s capability to consistently produce tiny holes that are even more accurate and with higher quality.
Software

How to Simplify Complex Geometry Tool Repair

By enabling the entry point of the grinding wheel to follow the corner radius of the cutting edge, the software now facilitates the grinding of a defined rake angle on complex body forms and on cutting edges which pass from the body of the tool to its tip – a task that was previously extremely difficult to achieve.
A new release of NUMROTO tool grinding software meets the growing challenges of grinding and servicing new generations of complex geometry drills and end mills.
Vertical Machining Centers

Before You Buy That VMC

A vertical machining center should have a robust spindle design with exceptional horsepower, superior torque and wide-ranging spindle speed that cuts a wide variety of materials in reduced cycle times.
When investing in a new production vertical machining center, take time to evaluate these seven critical features that have the greatest impact on the productivity and profitability of that machine tool.
Wire EDM Machines

Improving Profitability with User-Friendly EDM

Providing unrestricted access to the work zone and workpiece – including the bottom side of the workpiece and the machine’s lower head – bring efficiency to part production by reducing operator fatigue and errors, accelerating part changes and eliminating potential interference problems.
The complicated nature of the work and the current labor issues facing the industry mean that more user-friendly EDM is critical for your shop operation.
Metal Cutting: Products

HOUSTEX 2015

Booth 441: The versatile Thread Chaser tool from Seco Tools has inserts for both push and pull threading of ID features using multi-tooth patterns for fast single- or two-pass threading. The system’s multi-tooth inserts have precise thread patterns that quickly and reliably generate high-accuracy, consistently perfect thread pitches for industry-specific parts and pipe materials in a wide range of hardness.
Hundreds of exhibitors will highlight the latest manufacturing technologies for parts suppliers to the oil and gas industry and other related market sectors at this year’s event in the George R. Brown Convention Center in Houston on February 24-26, 2015. Here is a review of some of the machinery and tooling that will be on display.

Catch the Wave(form)

With Rough Waveform Turning, the toolpath maintains a constant cutting load, enabling significantly faster cutting data, and prolonging tool life. The cycle is sensitive to the stock condition, eliminating ‘fresh-air cuts.’ (first view)
Waveform turning, multiple machining sequence support, ribbon bar and interface updates, and the inclusion of Wire EDM are the newest CAD/CAM game changers that machine shops need to compete in a global economy.

Powerful Lightweight Two-Speed Mag Drill

An LED light is built into the base of the magnet on the HMD905 portable magnetic drill that allows the operator to more efficiently and quickly line up the pilot with the holes center location in low light or no light conditions. 
The HMD905 portable magnetic drill from Hougen provides steel fabricators with a great power-to-weight ratio that offers more strength and torque in a small lightweight footprint.